Method of Monitoring Gear Grinding Operations

Abstract

A method for monitoring a grinding operation using a computer system is provided. The method includes determining, by the computer system, a first plurality of operating characteristics associated with a pre-grinding operation. The method also includes determining, by the computer system, a second plurality of operating characteristics associated with the grinding operation. The method further includes determining, by the computer system, a set of operating conditions based on the first plurality of operating characteristics with and the second plurality of operating characteristics. Moreover, the method includes comparing, by the computer system, the set of operating conditions with a set of predetermined operation conditions.

1 . A method of monitoring a grinding operation using a computer system, comprising:
 determining, by the computer system, a first plurality of operating characteristics associated with a pre-grinding operation;   determining, by the computer system, a second plurality of operating characteristics associated with the grinding operation;   determining, by the computer system, a set of operating conditions based on the first plurality of operating characteristics and the second plurality of operating characteristics; and   comparing, by the computer system, the set of operating conditions with a set of predetermined operating conditions.   
     
     
         2 . The method of  claim 1 , wherein the pre-grinding operation includes at least one of a turning operation, a boring operation, a hobbing operation, or a heat-treating operation. 
     
     
         3 . The method of  claim 2 , wherein the first plurality of operating characteristics includes at least one of turning parameters, hobbing parameters, boring parameters, or heat treating parameters. 
     
     
         4 . The method of  claim 3 , wherein
 the turning parameters includes at least one of a cutting speed, a feed of a turning tool, or a depth of cut, and   the hobbing parameters includes at least one of a cycle time, approach and overrun distances, a hob setting angle, a feed rate, a number of starts, or a feed depth.   
     
     
         5 . The method of  claim 3 , wherein
 the boring parameters includes at least one of a feed of a cutting tool, or a radius of the cutting tool, and   the heat treating parameters includes at least one of a temperature, cooling rate, or a heating time.   
     
     
         6 . The method of  claim 1 , wherein the second plurality of operating characteristics includes at least one of grinding parameters, dressing parameters, part parameters, wheel parameters, gear parameters, system variations, or a cost information. 
     
     
         7 . The method of  claim 6 , wherein
 the grinding parameters includes at least one of a feed of a grinding wheel, an infeed of the grinding wheel, or a wheel velocity,   the dressing parameters includes at least one of a speed ratio, a contact ratio, or infeed of a dressing tool, and   the part parameters includes at least one of a part number, a pitch line runout, index variations, or lead variations.   
     
     
         8 . The method of  claim 6 , wherein
 the system variations includes at least one of a stock division error, an axial tilt on fixture, or an alignment error, and   the cost information includes at least one of a tool pricing information, or a machine overhead information.   
     
     
         9 . The method of  claim 1 , wherein the set of operation conditions includes at least one of a grinding ratio, a burn threshold, a machine kinematic, a dressing frequency, or a surface finish calculation. 
     
     
         10 . The method of  claim 1 , further includes determining, by the computer system, a third plurality of operating characteristics associated with the grinding operation. 
     
     
         11 . The method of  claim 10 , wherein, the third plurality of operating characteristics includes at least one of a material removal rate, a burn profile, a surface finish information, or a profile deviation. 
     
     
         12 . The method of  claim 10 , further comprising:
 determining, by the computer system, whether the grinding operation produces acceptable gears based on the third plurality of operating characteristics; and   optimizing the grinding operation if the grinding operation do not produce acceptable gears.   
     
     
         13 . The method of  claim 12 , wherein optimizing includes optimizing one or more of the first plurality of operating characteristics, second plurality of operating characteristics, or third plurality of operating characteristics. 
     
     
         14 . A system for monitoring a grinding operation, the system comprising:
 a memory; and   a processor coupled to the memory, the processor being configured to:   determine a first plurality of operating characteristics associated with a pre-grinding operation,   determine a second plurality of operating characteristics associated with the grinding operation,   determine a set of operating conditions based on the first plurality of operating characteristics and the second plurality of operating characteristics, and compare the set of operating conditions with a set of predetermined operating conditions.   
     
     
         15 . The system of  claim 14 , wherein the processor is further configured to determine a third plurality of operating characteristics associated with the grinding operation. 
     
     
         16 . The system of  claim 15 , wherein the processor is further configured to:
 determine whether the grinding operation produces acceptable gears based on the third plurality of operating characteristics; and   optimize the grinding operation if the grinding operation does not produce acceptable gears.   
     
     
         17 . A method of monitoring a grinding operation using a computer system, comprising:
 determining, by the computer system, a first plurality of operating characteristics associated with a pre-grinding operation;   determining, by the computer system, a second plurality of operating characteristics associated with the grinding operation;   determining, by the computer system, a set of operating conditions based on the first plurality of operating characteristics and the second plurality of operating characteristics;   comparing, by the computer system, the set of operating conditions with a set of predetermined operating conditions; and   providing an indication, by the computer system, whether the grinding operation is a standard grinding process.   
     
     
         18 . The method of  claim 17 , wherein if the grinding operation is not a standard grinding process, providing an indication includes at least one of sounding an alarm, or providing visual warning signals. 
     
     
         19 . The method of  claim 18 , further includes adjusting one or more of the first plurality of operating characteristics and the second plurality of operating characteristics. 
     
     
         20 . The method of  claim 17 , wherein if the grinding operation is not a standard grinding process, ceasing the grinding operation.